Liquid-phase catalyst-assembly for chemical process tower

Abstract

An improved catalyst assembly for vapor/liquid contact towers. Catalyst media used to promote chemical reactions is secured substantially in the liquid phase of the tower, such as in the lower portion thereof for improving mass transfer efficiency. Unlike previous process tower assemblies, wherein distillation in conjunction with chemical reaction occurs in the vapor phase or in a mixed phase, the present invention substantially confines the reaction step to the liquid phase. In this manner, the reaction is less obstructive to vapor flow within the tower, promoting better mixing and diffusion of the feed components.

What is claimed is: 
     
       1. In a process column assembly utilizing catalyst media therein, wherein liquid flows continuously downwardly through at least a first downcomer onto a first tray and across the active area thereof through which vapor flows upwardly for interaction and mass transfer with the liquid before passing, therefrom by at least a second downcomer, the improvement comprises: a catalyst media adapted for securement in said process column assembly;   at least one catalyst support grid secured to said process column assembly and extending thereacross for the support of said catalyst media within said process column assembly;   said at least one catalyst support grid and said catalyst media are positioned in a liquid-only reaction region in said process column assembly where only said liquid flows continuously downwardly and said catalyst media is continuously flooded by said liquid which flows continuously downwardly for facilitating the interaction between constituents of the liquid flowing continuously downwardly through said process column assembly and chemical reaction of said constituents promoted by said catalyst media;   a first solid tray secured in said process column assembly in a position beneath any catalyst support grid that is secured above a tray through which vapor flows upwardly; and   means for removing said vapor from said process column assembly and preventing said vapor from being exposed to said liquid-only reaction region and to said catalyst media therein, said means for removing comprising a first vapor stream draw off disposed beneath any said first solid tray that is secured in said process column and positioned to remove all vapor therefrom and prevent its passage into said liquid-only reaction region of said process column assembly.   
     
     
       2. The apparatus as set forth in claim 1 further comprising a second catalyst media support grid secured to said process column assembly and extending thereacross, said second catalyst media support grid is separated from said at least one catalyst support grid to provide a space therebetween for securement of said catalyst media therebetween. 
     
     
       3. The apparatus as set forth in claim 1 wherein said liquid-only reaction region is disposed in a generally lower region of said process column assembly and wherein said at least one catalyst support grid is positioned in said liquid-only reaction region for securing said catalyst media in said generally lower region of said process column assembly. 
     
     
       4. The apparatus as set forth in claim 3 wherein said process column assembly is constructed with a plurality of trays disposed therein for facilitating the flow of liquid thereacross and the upward flow of vapor therethrough and wherein said liquid-only reaction region and said catalyst media therein are disposed beneath said plurality of trays. 
     
     
       5. The apparatus as set forth in claim 1 wherein said liquid-only reaction region is disposed in a generally intermediate region of said process column assembly and wherein said at least one catalyst support grid is positioned in said liquid-only reaction region for securing said catalyst media in said generally intermediate region of said process column assembly. 
     
     
       6. The apparatus as set forth in claim 1 wherein said liquid-only reaction region is disposed in a generally upper region of said process column assembly and wherein said at least one catalyst support grid is positioned in said liquid-only reaction region for securing said catalyst media in said generally upper region of said process column assembly. 
     
     
       7. An improved catalyst media assembly for a process column utilizing catalyst media therein for promoting a chemical reaction of liquid constituents, said process column being constructed for liquid to flow continuously downwardly to engage vapor flowing upwardly for interaction, and mass transfer with said liquid, the improvement comprises: apparatus within said process column for defining a liquid-only reaction region therein to receive the liquid flowing continuously downwardly and for segregating vapor flow therefrom;   said apparatus further including means for securing said catalyst media in said liquid-only reaction region of said process column where said catalyst media is continuously flooded by said liquid and means for the exclusion of vapor flow therethrough, said vapor exclusion means including a first solid tray secured in said process column in a position beneath any catalyst support grid that is secured above a tray through which vapor flows upwardly whereby said chemical reaction of liquid constituents in said liquid-only reaction region is confined to the liquid phase; and   said means for the exclusion of vapor flow also including means for removing said vapor from said process column and preventing said vapor from being exposed to said liquid-only reaction region and to said catalyst media therein, said vapor removal means comprising a first vapor stream draw off disposed beneath said first solid tray and positioned to remove all vapor therefrom and prevent its passage into said liquid-only reaction region of said process column.   
     
     
       8. The catalyst media assembly as set forth in claim 7 wherein said process column is constructed with a plurality of trays disposed in a liquid and vapor region thereof for facilitating the flow of liquid thereacross and the upward flow of vapor therethrough and wherein said liquid-only reaction region is disposed in a region of said process column segregated from said trays. 
     
     
       9. The catalyst media assembly as set forth in claim 7 wherein said liquid-only reaction region is disposed in a generally lower region of said process column and wherein a support grid is positioned in said liquid-only reaction region for securing said catalyst media in said generally lower region of said process column. 
     
     
       10. The catalyst media assembly as set forth in claim 7 wherein said liquid-only reaction region is disposed in a generally intermediate region of said process column and wherein a support grid is positioned in said liquid-only reaction region for securing said catalyst media in said generally intermediate region of said process column. 
     
     
       11. The catalyst media assembly as set forth in claim 7 wherein said liquid-only reaction region is disposed in a generally upper region of said process column and wherein a support grid is positioned in said liquid-only reaction region for securing said catalyst media in said generally upper region of said process column.